764 replies to this topic

[mighty mini jack]

Nice work fella, getting on with it!

Whats that bike i see in the background?

[danny2009]

Nice work fella, getting on with it!

Whats that bike i see in the background?

looks like a pushbike to me

projects looking good mate, keep at it

[Tupers]

Thanks for the comments guys, this is a really fun project to work on I just need to pick up the pace a bit. The bike in the back ground is a DMR Trail Star 26" with Hope big'un hubs, M4 Mono disc brakes , DMR cranks and some other shinny stuff.

Got a bit more done on the car today, cut some stuff, drilled some spot welds and got the other bin and the two vertical seat supports out. I would have got some shots with the Rover seats in the back but the spot weld drillbit is dead so I couldn't remove the hinge rail and set them in place.

[mk1leg]

comming on well since I last looked well done keep up the good work.......................

[Tupers]

More progress.

Nasty horrible rust.


Big 'ol holes.



Nice new metal and holes drilled for spots.


Plates welded up with spot weld holes plugged.

[Tupers]

So here's what I did today.

Made the closing about the rear sub mounts and got it welded in.


Cut some rust out of the inner rear stiffener and welded a new piece in.


Made up a plate to cover the majority of the hole a tacked it in place.

[Tupers]

A bit more progress it's all coming along rather nicely.

Started out like this.


Cut a plate to fill the first hole and made a template for the second.


Made the next plate.


Drilled some holes for spot welds and got it welded in.


Got the plate on the back spotted and butt welded.

[mighty mini jack]

Nice repair there Fella, Its all coming together now!

[feybrand]

thats a cracking looking car nice colour 2 not so sure about the interior though but it does fit with the look

[Tupers]

Thanks for the comments guys, been doing a few more bits on the estate. As I've gotten rid of the rear bins I decided to extended the area where the rear seat will mount right across to the outed skin of the body. So I made a a plate for it and painted both surfaces in red oxide. I also made a new section for the lower door frame as the original was rather rotten.

Did the welding on this bit myself, it could be better but I'm pretty happy with it.




Red oxided.




Sat in place.


Welded in.


Here's the rotten piece on the right and the new metal on the left. Don't you just love rust, I know I do.


Sat in place to check fitment.


And now welded, ground and linished. It still need a bit of work it getting there.

[mk3 Cooper S]

Your panel making skills are excellent.
Keep up the good work.

[Tupers]

Today I thought I should fill in the last of the holes in the drivers side rear end.


Made a plate and got it welded in.


Ground and linished the welds so it's now smooth with the rest of the floor.


Cut a piece of steel to replicate the original flange that's still present on the other side.



And got it in place ready to drill holes for spot welding and mig along the bottom edge.


And while I had the linisher out I though I'd make a start on taking the weld down around the big plate in the floor.




I'll be giving the same treatment to the panel I made for the floorpan but grinding and linishing it from of the outside so it looks tidy from underneath.


Oh and I made the whole shell 5.9KG light by removing all the sound deadening from the floor.

Here's what I took out, the mug wasn't part of the floor though.


And heres what it looks like now.

[Tupers]

Didn't get much done today because we're still waiting on cutting discs to arrive but I did manage to get the tab I made welded.

Holes drilled for sport weld.


Miged along the bottom and ground smoothish. It still needs a bit of work with the diegrinder.


Spot welds 'erm welded.



I also cut of a chunk of rust from one of the turrets, welded a new plate is and got it all ground and linished down.

Hole cut.


New metal welded in, ground down, and linished. (I forgot to take a picture of it welded)


Welded again from the other side to make sure it's uber strong.

[Tupers]

I got loads more rust cut out of the rear arch and crossmember area to and made a start on folding the metal that I fill the gaping hole I was left with.

Started the morning a little worse than this.






Got to cutting.






Folded the first panel/plate and set it place to make sure the bends where right.


And they where so I trimmed it down and folded the last edge that will sport weld to the arch from the inside.

[Tupers]

Did some more on the back end today.

Made a new end piece for the rear crossmember.


Sat the it in with the floor panel to check fitment.


Folded up a nice 90* piece for the back of the arch to spot to.


Went through a few different templates and made up this panel for the back of the arch.


And last but not least got the floor panel welded in and red oxided it.



So if I do decide to work tomorrow I should be able to the rest of this arch buttoned up and start to cut rust out of some other part of this thing.